Prefabricated, Customizable Coffered Ceiling System

ABSTRACT

Systems and methods for providing a prefabricated, custom coffered ceiling apparatus, which includes an outer box frame, custom interior frame designs in accordance with an order, wherein the interior frame designs are attached to the outer box frame, and crown molding on the outside of the box frame at the top of the coffer. The coffers are finished with paint or various wood finished in accordance with an order. The coffer system is easily assembled via a groove created at the top of the coffer for easy installation at the desired location. Lighting fixtures or other desired elements may be mounted within the apparatus.

CROSS REFERENCE TO RELATED APPLICATION

This application takes priority from and claims the benefit of U.S. Provisional Application Ser. No. 62/474,356 filed on Mar. 21, 2017, the contents of which are herein incorporated by reference.

FIELD OF THE INVENTION

The present system, method and series of accompanying apparatuses relate to a system and method for prefabricated customizable coffered ceilings for delivery and easy installation in the desire location of consumers.

BACKGROUND OF THE INVENTION

A coffer in architecture is a series of sunken panels in the shape of a square, rectangle or octagon in a ceiling, soffit or vault. These panels are used for decoration for a ceiling or vault.

The oldest examples of coffers are the stone coffers used by the ancient Romans and Greeks. Modern coffers are constructed out of wood and other light-weight materials. In addition to the traditional shapes, coffers today can also be circular. Coffers may cover the entire ceiling or a small portion. They can be virtually any color, size, design and material. Construction often takes place at the customer's desired location by a professional crew where the coffers are assembled and installed directly onto the ceiling.

Coffers can be constructed in one of two ways. The first way coffers are created is by adding material to the ceiling, such as beams, to create a grid-like shape which gives the impression that there are sunken spaces in between. The second way is to remove ceiling material, such as when carving a hole or pressing into a flat surface to create an indentation. The first option takes away from the height of the ceiling but is more cost effective and takes less time. The second way involves a lot of skill and time and all the work is done directly to the ceiling.

SUMMARY OF THE INVENTION

The instant apparatus and method, as illustrated herein, is clearly not anticipated, rendered obvious, or even present in any of the prior art mechanisms, either alone or in any combination thereof. The versatile system, and series of apparatuses relating to coffered ceilings, prefabricated and customizable, and particularly an easy to create, install and uninstall method for coffered ceilings are illustrated. Thus the several embodiments of the instant apparatus are illustrated herein.

It is therefore an objective of the instant system to create a novel method for creating a prefabricated, customizable coffered ceiling apparatus.

It is therefore an objective of the instant system to create a novel method for creating a prefabricated, customizable coffered ceiling apparatus for the purpose of easy creation and assembly.

It is also an objective of the instant system to introduce a novel method for creating a prefabricated, customizable coffered ceiling apparatus for the purpose of easy instillation and removal.

It is also an objective of the instant system to introduce a novel method for creating a prefabricated, customizable coffered ceiling apparatus for the purpose of easy instillation, removal and reinstallation by the consumer.

An additional objective of the instant system is to provide a novel method for creating a prefabricated, customizable coffered ceiling apparatus by way of a method that is efficient which allows for more customizable options for consumers.

Additionally, it is the object of this system to have a novel method for creating a prefabricated, customizable coffered ceiling apparatus by way of a method that is capable of being assembled outside of the consumer's location.

It is also an additional object of the instant system to have a novel method for creating a prefabricated, customizable coffered ceiling apparatus that is capable of accommodating lighting and other ceiling fixtures.

It is also an additional object of the instant system to have a novel method for creating a prefabricated, customizable coffered ceiling apparatus that is inexpensive.

An additional object of the instant system to have a novel method for creating a prefabricated, customizable coffered ceiling apparatus that is easy to use.

These together, with the other objectives of the device, along with the various features of novelty, which characterize the method and apparatus, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the mechanism, its operating advantages, and the specific objectives attained by its use, study of the accompanying drawings and descriptive matter, in which there are illustrations of the preferred embodiments, should be conducted.

There has thus been outlined, rather broadly, the more important features of the versatile integrated Instant System, and series of accompanying systems and apparatuses and embodiments in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.

In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the method is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The method is capable of other procedures and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

These together with other objects of the invention, along with the various features of novelty, which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention.

To the accomplishment of the foregoing and related ends, certain illustrative aspects are described herein in connection with the following description and the annexed drawings. These aspects are indicative of the various ways in which the principles disclosed herein can be practice and all aspects and equivalents thereof are intended to be within the scope of the claimed subject matter. Other advantages and novel features will become apparent from the following detailed description when considered in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment illustrating a single coffer apparatus.

FIG. 2 is a cross sectional view of one embodiment illustrating a single coffer apparatus.

FIG. 3 is a top plan view of one embodiment illustrating a single coffer apparatus.

FIG. 4 is a top view of another embodiment illustrating a single coffer apparatus.

FIG. 5 is a top view of another embodiment illustrating a single coffer apparatus.

FIG. 6 is a top view of another embodiment illustrating a single coffer apparatus.

FIG. 7 is a top view of another embodiment illustrating a single coffer apparatus.

FIG. 8 is a top view of another embodiment illustrating a single coffer apparatus.

FIG. 9 is a perspective view of one embodiment illustrating a single coffer apparatus installed on a ceiling with lighting installation.

FIG. 10 is a perspective view of another embodiment illustrating a single coffer apparatus installed on a ceiling.

FIG. 11 is a flow chart of the manufacturing and installation processes of the present apparatus.

FIG. 12 is a top plan view of an additional embodiment of the single coffer apparatus comprising six equally proportioned rectangular recessed sections.

FIG. 13 is a top plan view of an additional embodiment of the single coffer apparatus comprising four equally proportioned rectangular recessed sections and a chamfered edge at the corner closest to the center section of the single coffer apparatus.

FIG. 14 is a top plan view of an additional embodiment of the single coffer apparatus comprising four equally proportioned rectangular recessed sections.

FIG. 15 is a top plan view of an additional embodiment of the single coffer apparatus comprising four equally proportioned rectangular recessed sections in the outer portion, as well as four equally proportioned rectangular recessed sections in an inner portion, which possess a chamfered edge at the corner closest to the center section of the single coffer apparatus.

FIG. 16 is a top plan view of an additional embodiment of the single coffer apparatus comprising eight equally proportioned rectangular recessed sections.

FIG. 17 is a top plan view of an additional embodiment of the single coffer apparatus comprising six equally proportioned rectangular recessed sections in the outer portion, as well as six equally proportioned rectangular recessed sections at the inner portion of the single coffer apparatus.

FIG. 18 is a top plan view of an additional embodiment of a single coffer apparatus comprising four equally proportioned rectangular recessed sections which possesses a rectangular chamfered edge at the corner closest to the center section of the single coffer apparatus.

FIG. 19 is a top plan view of an additional embodiment of a single coffer apparatus comprising six equally proportioned rectangular recessed sections in the outer portion, as well as six equally proportioned rectangular recessed sections at the inner portion of the single coffer apparatus.

DETAILED DESCRIPTION OF THE INVENTION

The detailed description set forth below is intended as a description of presently preferred embodiments of the invention and does not represent the only forms in which the instant invention may be construed and/or utilized. However, it is to be understood that the same or equivalent functions may be accomplished by different embodiments and are also intended to be encompassed within the scope of the invention.

FIG. 1 illustrates one embodiment comprising a single coffer apparatus further comprising at least one groove 12 at least one outer beam 16 and at least one inner beam 18. The at least one outer beam 16 is in communication with the at least one inner beam 18. The at least one groove 12 is in communication with the at least one outer beam 16. In one embodiment, the at least one outer beam 16 and the at least one inner beam 18 are fabricated from plywood. The instant embodiment contains four recessed sections 14 which possess depth and create can be utilized in the current structure, or in conjunction with lighting, or ornamental features.

FIG. 2 illustrates a cross-sectional view of one corner of the present apparatus 38 comprising a bolt hardware 20, metal plate 22, crown molding 26, flat casing 28, at least two beams 30, 36, and at least two side beams 32, 40. The at least two beams comprise a top beam 36 and a bottom beam 30. The top beam 36 is in communication with the existing ceiling 24. Below the top beam 36 is a designated space for optional electrical mechanisms 34. The top and bottom beams 30, 36 are in perpendicular communication the side beams 32, 39, 40 with each end of the top and bottom beams 30, 36 in communication with one of the four sides of the side beams 32, 39, 40. The flat casing 28 is in parallel communication with side beam 40, in perpendicular communication with side beam. 39, and in perpendicular communication with the bottom beam 30. The crown molding 26 is in communication with the flat casing 28 at one end, extending at a diagonal, with the other end in communication with the existing ceiling 24. The metal plate 22 is in communication with the existing ceiling 24, the top beam 36, and the bolt hardware 20. The bolt hardware 20 is inserted and extends though the top beam 36, metal plate 22, and existing ceiling 24. In one embodiment, the top beam 36, bottom beam 30, and side beams 32, 39, 40 are fabricated from plywood.

FIG. 3 illustrates a top plan view of one embodiment of the present apparatus comprising a single coffer apparatus comprising a cross-beam design 42 in the center. The cross-beam design 42 is in communication with the at least one outer beam 16.

FIG. 4 illustrates a top plan view of one embodiment of the present apparatus comprising a single coffer apparatus 54 comprising a cross-beam design 42, in the center, further comprising a diamond-shaped design 44 in the center of the cross-beam design 42. The diamond-shape design 44 is in communication with the cross-beam design 42 which is in further communication with the at least one outer beam 16.

FIG. 5 illustrates a top plan view of one embodiment comprising a single coffer apparatus 64 of the present apparatus comprising across-beam design 42 in the center, further comprising a rectangle-shaped design 46 in the center of the cross-beam design 42. The rectangle-shaped design 46 is in communication with the cross-beam design 42 which is in further communication with the at least one outer beam 16.

FIG. 6 illustrates a top plan view of one embodiment of the present apparatus comprising a single coffer apparatus 56 comprising a triple cross-beam design 58 in the center, further comprising at least one diamond-shaped design 44 in the center of each intersection of the triple cross beam design 58. The at least one diamond-shaped design 44 is in communication with the triple cross-beam design 58 which is in further communication with the at least one outer beam 16.

FIG. 7 illustrates a top plan view of one embodiment comprising a single coffer apparatus 62 of the present apparatus comprising a cross-beam design 42, in the center, further comprising a circular-shaped design 50 in the center of the cross-beam design 42. The circular-shaped design 50 is in communication with the cross-beam design 42 which is in further communication with the at least one outer beam 16.

FIG. 8 illustrates a top plan view of one embodiment comprising a single coffer apparatus 60 of the present apparatus comprising a double cross-beam design 52 in the center. The double cross-beam design 52 is in communication with the at least one outer beam 16.

FIG. 9 illustrates a perspective view of one embodiment comprising a single coffer apparatus 66 of the present apparatus comprising crown molding 26, flat casing 28, at least one outer beam 16, a cross-beam design 52 in the center of the at least one outer beam 16, further comprising a rectangle-shaped design 46 in the center of the cross-beam design 42, at least one cavity 70, and at least one light mechanism 68. The rectangle-shaped design 46 is in communication with the cross-beam design 42 which is in further communication with the at least one outer beam 16. The flat casing 28 is in communication with the at least one outer beam 16 and the crown molding 26. The crown molding is in further communication with the existing ceiling 24. The at least one light mechanism 68 is in communication with the existing ceiling 24 in the center of the cavity 70.

FIG. 10 illustrates a perspective view of one embodiment comprising a single coffer apparatus 72 of the present apparatus comprising crown molding 26, flat casing 28, at least one outer beam 16, a cross-beam design 74 in the center of the at least one outer beam 16, further comprising a square-shaped design 76 with a square-shaped cut-out hollow center 78 in the center of the cross-beam design 74, at least one cavity 70, and a false ceiling panel 79. The cross-beam design 74 is in communication with the at least one outer beam 16. The flat casing 28 is in communication with the at least one outer beam 16 and the crown molding 26. The crown molding is in further communication with the existing ceiling 24. The false ceiling panel 79 is in communication with the at least one outer beam and in further communication with the flat crown molding 26.

FIG. 11 illustrates a flow chart of order receiving, manufacturing and installation processes of the present system and associated apparatuses. The method begins with a customer order that is processed 82. Once processing is complete, the outer box frame materials are sent to the shop to be cut 84 according to the dimensions of the selected coffer apparatus. Next, the outer box frame structure is fabricated and assembled 86. Subsequently, the remaining structural elements, such as the interior frame design, are fabricated as well as any additional custom elements 88, as required. Next, the components are assembled 90 followed by the finishing process where paint and/or materials are added 92.

The groove is then fabricated and assembled at the top of the coffer 94 to allow for easy instillation and removal of the present apparatus. Lastly, the completed coffer is delivered and installed at the desired location 96 followed by any additional elements such as lighting 98.

FIG. 12 illustrates a top plan view of an additional embodiment of a single coffer apparatus 100 comprising a cross-beam design 42 and also comprising six equally proportioned rectangular recessed sections 110 which possess depth and create can be utilized in the current structure, or in conjunction with lighting, or ornamental features.

FIG. 13 illustrates a top plan view of an additional embodiment of a single coffer apparatus 101 comprising a cross-beam design 42 and also comprising four equally proportioned rectangular recessed sections 111, which possess a chamfered edge 111 at the corner closest to the center section of the single coffer apparatus 101.

FIG. 14 illustrates a top plan view of an additional embodiment of a single coffer apparatus 102 comprising a cross-beam design 42 and also comprising four equally proportioned rectangular recessed sections 112.

FIG. 15 illustrates a top plan view of an additional embodiment of a single coffer apparatus 103 comprising a cross-beam design 42 and also comprising four equally proportioned rectangular recessed sections 113 in the outer area, as well as four equally proportioned rectangular recessed sections 114 in the inner area and these possess a chamfered edge 114 at the corner closest to the center section of the single coffer apparatus 103.

FIG. 16 illustrates a top plan view of an additional embodiment of a single coffer apparatus 104 comprising a cross-beam design 42 and also comprising eight equally proportioned rectangular recessed sections 115.

FIG. 17 illustrates a top plan view of an additional embodiment of a single coffer apparatus 105 comprising a cross-beam design 42 and also comprising six equally proportioned rectangular recessed sections 116 in the outer area, as well as six equally proportioned rectangular recessed sections 117 at the inner portion of the single coffer apparatus 105.

FIG. 18 illustrates a top plan view of an additional embodiment of a single coffer apparatus 106 comprising a cross-beam design 42 and also comprising four equally proportioned rectangular recessed sections 118, which possesses a rectangular chamfered edge 118 a at the corner closest to the center section of the single coffer apparatus 106.

FIG. 19 illustrates a top plan view of an additional embodiment of a single coffer apparatus 107 comprising a cross-beam design 42 and also comprising six equally proportioned rectangular recessed sections 119 in the outer area, as well as six equally proportioned rectangular recessed sections 120 at the inner portion of the single coffer apparatus 107. 

What is claimed is:
 1. A ceiling coffer apparatus, comprising: at least one outer beam; at least one inner beam; at least one cavity; at least one groove; a set crown molding fittings; a flat casing; and a finishing material.
 2. The ceiling coffer apparatus of claim 1, wherein the at least one outer beam is in communication with the at least one inner beam.
 3. The ceiling coffer apparatus of claim 1, wherein the flat casing is in communication with the at least one outer beam and in further communication with the crown molding.
 4. The ceiling coffer apparatus of claim 1, wherein the at least one inner beam, in comprises a cross-beam design wherein the cross-beam design comprises a shaped portion.
 5. The ceiling coffer apparatus of claim 1, wherein the shaped portion of the cross-beam design comprises a shape selected from the group consisting of a diamond-shape design at a center portion, a rectangle-shaped design at a center portion, a circular-shaped design at a center portion, a double cross-section design, a triple cross-section design with at least one diamond-shaped design at the center of each intersection.
 6. The ceiling coffer apparatus of claim 1, wherein the at least one cavity is in communication with at least one lighting mechanism.
 7. The ceiling coffer apparatus of claim 1, further comprising a false ceiling panel wherein the false ceiling panel is in communication with the at least one outer beam, completely covering the portion of the existing ceiling encompassed by the ceiling coffer apparatus and wherein the false ceiling panel is in further communication with the crown molding.
 8. The ceiling coffer apparatus of claim 1, wherein the finishing material comprises paint grade, mahogany, walnut, oak, white oak, pine, or distressed lumber.
 9. A method to create and assemble a prefabricated coffer apparatus, comprising the steps of: a. measuring, fabricating and assembling the outer box frame; b. measuring, fabricating and assembling the interior frame design and any additional customer specified design elements; c. assembling of the outer box frame, interior frame design and any additional customer specified design elements; d. finishing the coffer apparatus with paint or chosen wood finish as desired by the customer; e. fabricating a groove for use in installation of coffer apparatus to the desired ceiling; f. delivering and installing the coffer apparatus at the desired location; and, g. installing at least one lighting element.
 10. The method to create and assemble a prefabricated coffer apparatus of claim 9, wherein the prefabricated coffer apparatus comprises: at least one outer beam; at least one inner beam; at least one cavity; at least one groove; a set crown molding fittings; a flat casing; and a quantity of finishing material.
 11. The method to create and assemble a prefabricated coffer apparatus of claim 9, wherein the measuring step, fabricating step and assembling step of the interior frame are accomplished by measuring the materials, cutting the materials to pre-determined sizes, and assembling the materials to fabricate the interior frame design.
 12. The method to create and assemble a prefabricated coffer apparatus of claim 9, wherein the measuring step, fabricating step and assembling step of the outer box frame are accomplished by measuring the materials, cutting the materials to pre-determined sizes, and assembling the materials to fabricate the outer box frame.
 13. The method to create and assemble a prefabricated coffer apparatus of claim 10, wherein each individual of the at least one outer beams comprises an outer beam end and wherein each individual of the outer beam ends is in mechanical communication with the adjacent individual of the outer beam ends.
 14. The method to create and assemble a prefabricated coffer apparatus of claim 10 wherein the flat casing is in communication with the at least one outer beam and in further communication with the crown molding.
 15. The method to create and assemble a prefabricated coffer apparatus of claim 10 wherein the at least one inner beam, in one embodiment, comprises a cross-beam design wherein the cross-beam design comprises a shaped portion.
 16. The method to create and assemble a prefabricated coffer apparatus of claim 15 wherein the shaped portion of the cross-beam design comprises a shape selected from the group consisting of a diamond-shape design at a center portion, a rectangle-shaped design at a center portion, a circular-shaped design at a center portion, a double cross-section design, a triple cross-section design with at least one diamond-shaped design at the center of each intersection.
 17. The method to create and assemble a prefabricated coffer apparatus of claim 10 wherein the at least one cavity is in communication with at least one lighting mechanism.
 18. The method to create and assemble a prefabricated coffer apparatus of claim 10 further comprising a false ceiling panel wherein the false ceiling panel is in communication with the at least one outer beam, completely covering the portion of the existing ceiling encompassed by the ceiling coffer apparatus and wherein the false ceiling panel is in further communication with the crown molding.
 19. The method to create and assemble a prefabricated coffer apparatus of claim 10 wherein the assembling of the outer box frame and interior frame comprises the interior frame design in communication with the interior of the outer box frame at the cross section of any interior frame design beams. 